Articles comprising impregnated thermoplastic members and method of manufacturing the articles

ABSTRACT

An article, including disposable articles and durable articles, includes one or more shaped thermoplastic members, which can be at least partially impregnated into one or more fibrous substrates forming a composite material of the article having regions of breathability, elasticity, and/or stiffening to provide desired functions of the article. The shaped thermoplastic members have a profiled thickness and/or basis weight providing variation in material properties. A percent variation of the profiled thickness of the thermoplastic member can vary from about 5% to about 95%. A process for manufacturing the composite material of the present invention is also disclosed.

FIELD OF THE INVENTION

[0001] The present invention relates to disposable and durable articles,such as disposable diapers, pull-on diapers, incontinence briefs,feminine hygiene articles, baby bibs, and the like, and durable articlesincluding sportswear, outerwear and the like, which comprise one or morethermoplastic members of polymeric materials impregnated into a fibroussubstrate to provide desired properties, and a method of manufacturingthereof.

BACKGROUND

[0002] Disposable and durable articles require many specific materialproperties needed to provide desired performance functions, which areoften difficult to provide using conventional methods of manufacture.For example, disposable absorbent articles, such as baby diapers, havemany designs providing desired product performance in collecting andretaining urine and bowel movement (BM) without leaking outside thediaper. These functions need to be performed together with otherfunctions in providing certain comfort to a wearer or user of the diaperduring application, wear and disposal of the diaper. Comfort can beaffected by effective functions of collecting and separating theexudates from the skin of the wearer, by providing a good initial fit ofthe diaper around the wearer and maintaining the fit during the use sothe diaper does not sag and leak when becomes loaded with exudates.

[0003] Good fit around the body of the wearer is generally provided bycreating elasticized areas in certain locations of the diaper. Examplesof such elasticized areas include elastic leg cuffs, elastic waistband,elastic side panels, and others. The desired elastic properties in suchareas are normally provided by various techniques, which generallyinclude creation of composite materials by laminating elastic materialswith nonwoven substrates. The elastic materials typically include anelastic film, single or multiple elastic strands, an elastic scrim, andthe like. The elastic materials are typically bonded to nonwovensubstrates by adhesives, thermal bonding, ultrasonic bonding, pressurebonding, and the like. However, this practice is expensive because itgenerally needs substantial amounts of elastic materials, whichgenerally are considerably more expensive than nonwoven materials.Because elastic materials are typically bonded with nonwoven materials,the cost includes both the cost of adhesives and the cost of adhesiveoperations. Further, prior to the bonding of the elastic materials tothe non-woven substrates, the elastic materials typically requireprocess operations to form the elastic materials into desired sizes andshapes. Such operations can be called secondary operations and ofteninclude un-winding, feeding, cutting, slitting, gluing, and the like.Due to the physical properties of elastic materials, they are oftendifficult to handle, often requiring special modifications to make aspecific elastic material process-friendly, i.e., easier to handle.Furthermore, these secondary operations often result in waste of elasticmaterials in the form of trim and/or scrap.

[0004] Further, with respect to the elasticized areas of the diaper,these areas often require profiled elasticity (varying elasticity),which is often difficult to provide. Examples of profiled areas ofelasticity can include side panels, elastic waists, and leg elasticcuffs, providing both comfort and sustained fit.

[0005] Therefore, it would be beneficial to provide elasticizedmaterials, comprising reduced amounts of elastic materials. Further, itwould be beneficial to provide elasticized materials, production ofwhich does not require the use of secondary operations. Further, itwould be beneficial to provide elasticized materials having varyingdegrees of elasticity in desired areas of the product.

[0006] Good comfort during the wear and use of the diaper can begenerally provided by use of breathable materials comprising the diaper.For example the outer cover of the diaper can be vapor permeable.Further, the diaper can be designed to have breathable, but liquidimpervious elasticized cuffs around the legs; breathable elasticizedwaist; breathable elasticized side panels; and breathable butliquid-impervious backing layer. This is generally accomplished bybonding thermoplastic materials, like porous or nonporous films, scrims,or strands to a nonwoven substrate. Again, this approach incurs morecost for thermoplastic materials and secondary operations. Further, oneimportant attribute of breathability is providing a varying degree ofbreathability in desired areas of the article. This is difficult andexpensive to accomplish in utilizing the lamination technology.Therefore, it would be beneficial to provide breathable materials havingvarying degrees of breathability and comprising reduced amount ofthermoplastic materials and which do not require the use of secondaryoperations described above.

[0007] Further, a disposable diaper that provides functions ofcollecting and retaining urine and BM without leakage outside the diaperrequires a fastening system to allow for desired closure of the articlearound torso of the wearer. Examples of fastening systems includehook-and-loop fastener systems and adhesive tape fastening systems,which require substantial mass of thermoplastic material to providedesired material physical properties such as strength and stiffness.Another example of a fastening system includes the slot and tab fastenerrequiring specific shape or configuration, which is difficult to provideutilizing the lamination technology. Therefore, it would be beneficialto provide a material of the desired shape comprising less mass ofthermoplastic material and does not require the secondary operations,described above.

[0008] Further, the fastening systems require varying degrees ofstiffness and strength for both functional and comfort purposes. This isdifficult to accomplish using the lamination technology because, asabove, it requires more thermoplastic material and secondary operations.Therefore, it would be beneficial to provide a material having variabledegree of stiffness and strength in specific areas comprising less massof thermoplastic material and which does not require the secondaryoperations, as described above.

[0009] Further, the comfort of the wearer is affected by the surfacetexture of the material contacting the skin of the wearer and/orcaregiver, as well as aesthetic appearance of the material itself. Thisis difficult to accomplish using lamination technology. In addition, itrequires additional thermoplastic materials and secondary operations tomask undesirable characteristics of material surfaces. For example, anouter cover, which comprises a nonwoven web laminated to the outersurface of a thermoplastic film, provides a cloth-like appearance of theouter cover. Another example includes tapes comprising a nonwoven weblaminated to the outer surface of a thermoplastic film to provide aclothlike appearance. Therefore, it would be beneficial to provide amaterial having a desired surface texture and aesthetic appearancecomprising less mass of thermoplastic material and which does notrequire secondary operations, as described above.

[0010] With respect to durable articles, the desired material propertiessuch as elasticity, breathability, stiffness, strength and the like aredifficult to provide using conventional manufacturing techniquesincluding sewing, ultrasonic welding, and the like, of expensive fabricshaving the desired properties. As disclosed above, these techniquesrequire more material (thermoplastics and others) and secondaryoperations associated with cutting, sewing, and assembling. Therefore,it would be beneficial to substitute the expensive materials with lessexpensive materials comprising impregnated thermoplastic members havingthe desired properties and to reduce the secondary operations associatedwith cutting, handling, sewing, and bonding of durable articles.

SUMMARY OF THE INVENTION

[0011] In response to the difficulties and problems discussed above, anew article and a process for producing thereof have been discovered.

[0012] In one aspect, the present invention concerns an articleincluding one or more shaped thermoplastic members at least partiallyimpregnated into one or more fibrous substrates forming a compositematerial, wherein the shaped thermoplastic members have a profiledthickness providing variation in material properties, and wherein apercent variation of the profiled thickness of the thermoplastic membercan vary from about 5% to about 95%.

[0013] In another aspect, the present invention concerns a method ofmaking a composite material including at least one shaped thermoplasticmember impregnated into at least one fibrous substrate, the methodincluding the steps of:

[0014] a) providing a first fibrous substrate;

[0015] b) depositing a first thermoplastic material on the first fibroussubstrate to form at least one shaped thermoplastic member having aprofiled thickness providing variation in material properties, wherein apercent variation of the profiled thickness of the thermoplastic membercan vary from about 5% to about 95%, and wherein the step of depositingis selected from a group consisting of intaglio printing, gravureprinting, screen printing, ink jet printing, and flexographic printing;

[0016] c) providing a second substrate; and

[0017] d) combining the first substrate and the second substrate to formthe composite material, wherein the thermoplastic member is at leastpartially impregnated into the first substrate.

[0018] In still another aspect, the present invention concerns acomposite material including one or more shaped thermoplastic members,at least partially impregnated into one or more fibrous substratesforming the composite material, wherein the shaped thermoplastic membershave a profiled thickness providing variation in material properties,and wherein a percent variation of the profiled thickness of thethermoplastic member can vary from about 5% to about 95%.

BRIEF DESCRIPTION SHOWN IN THE DRAWINGS

[0019] While the specification concludes with claims particularlypointing out and distinctly claiming the subject matter which isregarded as the present invention, it is believed that the inventionwill be more fully understood from the following description taken inconjunction with the accompanying drawings, in which:

[0020]FIG. 1 is a perspective view of one embodiment of a disposableabsorbent article of the present invention;

[0021]FIG. 2 is a magnified view of one embodiment of an impregnatedthermoplastic member of the present invention;

[0022]FIG. 3 is a cross sectional view of the impregnated thermoplasticmember shown in FIG. 2 taken along line 3-3;

[0023]FIG. 4 is a cross sectional view of the impregnated thermoplasticmember shown in FIG. 2 taken along line 4-4;

[0024]FIG. 5 is a simplified illustration of one embodiment of a processof the present invention for fabrication of a composite material of thepresent invention; and

[0025]FIG. 6 is a magnified view of a printing cylinder pattern of theprocess shown in FIG. 5, and

[0026]FIG. 7 is a simplified illustration of another embodiment of aprocess of the present invention for fabrication of a composite materialof the present invention; and

[0027]FIG. 8 is a simplified illustration of yet another embodiment of aprocess of the present invention for fabrication of a composite materialof the present invention;

[0028]FIG. 9 is a simplified illustration of an apparatus used fordetermining the dynamic fluid transmission value.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The article and the method of manufacture of the presentinvention can provide a surprising improvement in cost by reducing theneed for thermoplastic materials and secondary process operationsassociated with cutting, forming, and bonding these materials to form adesired product. The article includes new composite materials comprisingat least one thermoplastic member at least partially impregnated in oneor more fibrous substrates of the article.

[0030] The impregnated thermoplastic members can have various basisweights and three dimensional shapes and profiles, which can result indesired variations in physical properties of the composite material. Theplaner shape in the x-y direction of the impregnated thermoplasticmembers can be any suitable geometrical shape defining the planerdimensions of the composite material, including a rectilinear outline, acurvilinear outline, a triangle, a trapezoid, a square, a parallelogram,a polygon, an ellipse, a circle, and any combination thereof. In thecross section of the member, its shape in the z direction can be anysuitable geometric shape including linear and nonlinear profiles. Thevariation of the impregnated thermoplastic member in the z direction canbe from about 5% to about 95%, preferably from about 20% to about 80%.The variation can extend in any direction in the x-y plane and can becalculated by the following formula:

Percent variation=100×(maximum thickness−minimum thickness)/maximumthickness.

[0031] The new composite materials of the present invention can havevarious material properties within the planer dimensions of thecomposite material, which can vary generally as a function of thevariation in thickness of the impregnated polymeric member. The newcomposite materials can include such unique materials propertiesincluding a relatively high ratio of modulus of elasticity to density, arelatively high ratio of tensile strength to density, and other ratiosprovided by a unique combination of a first material (a substrate,fibrous material) and a second material (a thermoplastic member)impregnated within the fibers of the first material. The unique materialproperty ratios result in cost benefits of the new composite materials.The lightness, flexibility, the tensile strength, the elasticity,porosity, and many other properties contemplated by the inventors can beprovided by the first material of the composite material. The secondmaterial can be impregnated within the fibers of the first material,forming the composite material. The second material can be provided withvarious material properties within the realm of polymers. For example, adesired tensile strength, a modulus of elasticity, elasticity,electrical and/or thermal conductivity, air breathability, liquidimpermeability, magnetism, and many other properties have beencontemplated by the inventors. It should be noted that the inventorshave contemplated many other utilizations of thermoplastic members andresulting composite materials. For example, one of the specificcontemplated utilizations of the above properties of the thermoplasticmembers can be in providing various envisioned, desired functions ofdetecting bodily functions of a wearer, including temperature, skincondition, relative humidity between the skin and the article, presenceof body extrudates, and the state of the capacity of the absorbentarticle.

[0032] Further, unique interrelationships between physical properties ofthe new composite materials can be formed, for example, a relativelyhigh ratio of modulus to density, a relatively high ratio of tensilestrength to density, providing cost benefits for the new compositematerial.

[0033] Similarly to the thickness profile described above, the basisweight of the composite material can also have a desirable profile.Similarly, the basis weight profile can be any suitable geometric shapeincluding linear and nonlinear profiles. The variation in basis weightof the composite material of the present invention across the x-y planecan be from about 5% to about 95%, preferably from about 20% to about80%, wherein this variation can be calculated by the following formula:

Percent variation=100×(maximum basis weight−minimum basisweight)/maximum basis weight.

[0034] Terminology

[0035] The term “article” herein includes both disposable and durablearticles.

[0036] The term “disposable” is used herein to describe products whichgenerally are not intended to be laundered or otherwise restored orextensively reused in their original function, i.e., preferably they areintended to be discarded after about 10 uses or after about 5 uses orafter about a single use. It is preferred that such disposable articlesbe recycled, composted or otherwise disposed of in an environmentallycompatible manner.

[0037] The term “durable” is used herein to describe products whichgenerally are intended to be laundered or otherwise restored orextensively reused in their original function, i.e., preferably they areintended to be used more than about 10 times.

[0038] A “disposable absorbent article” refers herein to a device thatnormally absorbs and retains fluids. In certain instances, the phraserefers to devices that are placed against or in proximity to the body ofthe wearer to absorb and contain the excreta and/or exudates dischargedfrom the body, and includes such personal care articles as baby diapers,baby training pants, adult incontinence articles, feminine hygienearticles, baby swim diapers, wound dressing, and the like. In otherinstances, the phrase refers to protective articles, such as, forexample, dining bibs that have the ability to absorb food items toprevent staining of the wearer's clothing.

[0039] The term “diaper” includes baby diapers, baby training pants,baby pool diapers, or adult incontinence articles and refers to adisposable fluid-handling article generally worn by infants and otherincontinent persons about the lower torso.

[0040] The term “feminine hygiene articles” refers herein to anyabsorbent article worn by women to absorb and contain menses and othervaginal exudates.

[0041] A “body wrap” refers herein to an article or a garment worn aboutthe body, typically to provide some therapeutic benefit, such as, forexample, pain relief, wound coverage or to hold another device orarticle near the body.

[0042] The term “breathable” is used herein to describe materials thatare permeable and transmittable to vapor, wherein the vapor transmissionrate is measured in grams per 24 hours.

[0043] The term “material” refers herein to any web, substrate, fibrousmaterial, woven, nonwoven, knitted, film, a component of a garment or anabsorbent article.

[0044] The term “web” is meant herein any continuous material, includinga film, a nonwoven fabric, a woven fabric, a foam or a combinationthereof, or a dry lap material including wood pulp, and the like, havinga single layer or multiple layers.

[0045] The term “substrate” is meant herein any material, including afilm, a non-woven fabric, a woven fabric, a foam or a combinationthereof, or a dry lap material including wood pulp, and the like, havinga single layer or multiple layers, and suitable for printing a polymericmaterial on at least one surface of the “substrate.”

[0046] A “fibrous substrate” means herein a material comprised of amultiplicity of fibers that could be either a natural or syntheticmaterial or any combination thereof. For example, nonwoven materials,woven materials, knitted materials, celluloid materials, and anycombinations thereof.

[0047] The term “nonwoven” refers herein to a fabric made fromcontinuous filaments and/or discontinuous fibers, without weaving orknitting by processes such as spun-bonding and melt-blowing. Thenon-woven fabric can comprise one or more nonwoven layers, wherein eachlayer can include continuous filaments or discontinuous fibers.

[0048] An “elastomer” refers herein to a polymer exhibiting elasticproperties.

[0049] The term “elastic”, “elastic properties” or “elasticized” refersherein to any material that upon application of a force to its relaxed,initial length can stretch or elongate to its elongated length withoutrupture and breakage, and which can substantially recover its initiallength upon release of the applied force.

[0050] A “natural material” means herein a material derived from plants,animals, insects or byproducts of plants, animals, and insects.Non-limiting examples of natural materials useful in the disposablearticles include celluloid fibers, cotton fibers, keratin fibers, silkfibers and the like. Non-limiting examples of celluloid fibers includewood pulp fibers, hemp fibers, jute fibers, and the like. Non-limitingexamples of keratin fibers include wool fibers, camel hair fibers, andthe like.

[0051] The term “stiffening region” refers herein to an area of amaterial having a greater modulus of elasticity than that of theadjacent areas of the material.

[0052] The term “elastic region” refers herein to an area of a materialhaving greater elastic properties than those of the adjacent areas ofthe material.

[0053] The term “breathable region” refers herein to an area of amaterial having a greater breathability (measured in grams per meter²per 24 hours of moisture vapor transmission rate MVTR) than that of theadjacent areas of the material.

[0054] An article of the present invention can best be understood byreference to FIG. 1 illustrating one embodiment of an absorbent articleof the present invention, specifically a disposable diaper 10. For easeof understanding, much of the following description will be made interms of the disposable diaper 10. The diaper 10 can comprise amultiplicity of impregnated thermoplastic members into nonwovensubstrates of the diaper 10, providing specific material propertiesand/or specific functions for the diaper 10, such as, for example, agasketing function around the legs of the wearer provided by an elasticregion 11 of the article expressed by a leg elastic 12; anothergasketing function around the waist of the wearer provided anotherelastic region 13 of the article expressed by the waist elastic 14; afit function around the torso provided another elastic region 15expressed by an elasticized side panel 16; a fastening function thatprovides closure for the diaper 10 is provided by a stiffening region 21and a stiffening region 23, expressed as a slot member 20 and tab member22, respectively, capable of engaging to effect a desired closure; and abreathable function for the diaper 10, provided by a breathable region25 expressed by the outercover 24 providing transmission of vaporsthrough the outercover 24, as well as a barrier for liquids includingwaste exudates.

[0055] In order to provide the above functions for the product, thethermoplastic members impregnated into fibrous substrates result in newcomposite materials having a variety of unique properties contributed bythe components of the new composite materials, which can provide desiredphysical properties at lower cost due to less polymeric materials thanneeded by conventional lamination technology. Because of the fibrousstructure, the resulting composite materials have lighter weight andgreater mechanical properties than the polymeric resin. The fibroussubstrate provides desired structural fibrous, network of generallyinterconnected fibers having desired tensile and stiffness properties.In addition, the percent fiber volume of the composite material canaffect the mechanical properties in the composite material. The percentfiber volume is defined as the volume of fibers inside an impregnatedmember divided by the total volume of the impregnated member.

[0056]FIG. 2 illustrates a magnified plan view of one embodiment of animpregnated thermoplastic member 30 of the present invention forming avoid 19 defined by the slot member 20 of the fastening system 18 (FIG.1). The void 19 is defined by a rectangular shape; however, the void 19can be defined by any suitable geometrical shape including a rectilinearoutline, a curvilinear outline, a triangle, a trapezoid, a square, aparallelogram, a polygon, an ellipse, a circle, and any combinationthereof. The impregnated thermoplastic member 30 provides the desiredrigidity and strength around a slot opening 32. The size of theimpregnated thermoplastic member 30 can vary in x-y-z directions,preferably from millimeters to meters in x-y direction, and from micronsto millimeters in the z direction. In one embodiment, the y dimension is80 mm, the x dimension is 25 mm, and the z dimension can vary along they-axis, from about 0.3 mm to about 1.0 mm in a desired profile thatyields a 70% thickness variation in the z dimension. In anotherembodiment, the y dimension is 80 mm, the x dimension is 25 mm, and thez dimension along the y-axis can vary from 0.05 mm to about 1.0 mm in adesired profile that yields a 95% thickness variation in the zdimension. In yet another embodiment, the y dimension is 80 mm, the xdimension is 25 mm, and the z dimension along the y-axis can vary from0.95 mm to about 1.0 mm in a desired profile that yields a 5% thicknessvariation in the z dimension. From the preceding embodiments one skilledin the art can see a wide range of thickness profile variation ispossible with the present invention and all intermediate values withinthis range of about 5% to about 95% are also contemplated.

[0057] Properties of the composite material depend upon the individualproperties of the polymeric member (resin), the individual properties ofa fibrous substrate, and the volume of fiber impregnated into thepolymeric member. In one embodiment of the present invention, thecomposite material of the slot and tab fastener system 18 (FIG. 1),including stiffening regions 21 and 23, comprises a polypropylenethermoplastic member 30 (FIG. 2) fabricated from a polypropylene resinsuch as BASELL 917 manufactured by Basell Polyolefins Company N.V. ofthe Netherlands and a polyester nonwoven substrate such as manufacturedby DuPont of Delaware under brand name SONTARA. The BASELL 917polypropylene resin has a modulus of elasticity of about 1200 MPa(Pascal×10⁶), and SONTARA polyester nonwoven fibers have a modulus ofelasticity of about 8900 MPa. The resulting composite material,comprising a fiber volume of SONTARA, ranging from about 10% to about90%, can have a modulus of elasticity ranging from about 1700 MPa toabout 8000 MPa, respectively, which is significantly greater than themodulus of elasticity of the thermoplastic polypropylene resin. Inanother embodiment of the present invention, the composite material ofthe slot and tab fastener system 18 comprises a polyethylenethermoplastic member fabricated from a polyethylene resin such as BASELLLupolen 3020 manufactured by Basell Polyolefins Company N.V. of theNetherlands and a polyester nonwoven substrate such as manufactured byDuPont of Delaware under brand name SONTARA. The BASELL Lupolen 3020polyethylene resin has a modulus of elasticity of about 300 MPa(Pascal×10⁶), and SONTARA polyester nonwoven fiber have a modulus ofelasticity of about 8900 MPa. The resulting composite material,comprising a fiber volume of SONTARA, ranging of about 10% to about 90%,can have a modulus of elasticity ranging from about 350 MPa to about6000 MPa, which is significantly greater than the modulus of elasticityof the thermoplastic polyethylene resin.

[0058] From the preceding embodiments one skilled in the art can see awide range of modulus of elasticity variation is possible with thepresent invention and all intermediate values within the full range ofabout 350 MPa to about 8000 MPa are also contemplated.

[0059] Further, in regards to the tensile strength of the fastenersystem 18, BASELL 917 polypropylene resin has a tensile strength ofabout 300 MPa, and SONTARA polyester nonwoven substrate fibers havetensile strength of about 1800 MPa. The resulting composite materialcomprising a fiber volume of about 10% to about 90% has a tensilestrength range of about 400 MPa about 1600 MPa, which is significantlygreater than the tensile strength of the thermoplastic polypropyleneresin.

[0060] In another embodiment of the present invention, the compositematerial of the slot and tab fastener system 18 comprises a polyethylenethermoplastic member fabricated from a polyethylene resin such as BASELLLupolen 3020 manufactured by Basell Polyolefins Company N.V. of theNetherlands and a polyester nonwoven substrate such as manufactured byDuPont of Delaware under brand name SONTARA. The BASELL Lupolen 3020polyethylene resin has a tensile strength from about 15 MPa(Pascal×10⁶), and SONTARA polyester nonwoven fibers have a tensilestrength of about 1800 MPa. The resulting composite material, comprisinga fiber volume of SONTARA ranging of about 10% to about 90%, can have atensile strength of about 25 MPa to about 1600 MPa, which issignificantly greater than the tensile strength of the thermoplasticpolyethylene resin.

[0061] From the preceding embodiments one skilled in the art can see awide range of tensile variation is possible with the present inventionand all intermediate values within the full range of about 25 MPa toabout 1600 MPa are also contemplated.

[0062] The profile of the impregnated thermoplastic member 30 (FIG. 1)can be any suitable geometric contour having a linear or nonlinearprofile. FIG. 3 illustrates a cross sectional view of the impregnatedthermoplastic member 30 shown in FIG. 2, taken along cross lines 3-3.The thermoplastic member 30 is preferably at least partially impregnatedinto both substrates 34 and 36, which are combined together to form anew composite material 38. In one embodiment, the cross section of themember 30 can have a generally uniform thickness in the z-direction withtapering 39 on the outer edges of the impregnated member 30. Tapering isdesired to provide flexibility at the edges to prevent discomfort to thewearer from stiff edges.

[0063] Similarly, FIG. 4 illustrates a cross sectional view of theimpregnated thermoplastic member 30 taken along cross lines 4-4, havinga profiled thickness 31. The shape of the profiled thickness 31 can beselected to provide a desired strength profile of the composite material38, specifically, the shape of the profiled thickness varies to provideadditional stiffness at the ends 35 of the impregnated thermoplasticmember 30 and more flexibility in the middle 37 of the impregnatedthermoplastic member 30.

[0064] The outer cover 24 of the diaper 10 shown in FIG. 1 includes athermoplastic member 26 to provide desired breathability of the outercover 24 while maintaining liquid impermeability of the outer cover 24.The thermoplastic member 26 can be made from a variety of polymericresins providing vapor permeability and liquid impermeability across thez direction. Examples of such materials can include monolithicpolyesters like HYTREL manufactured by DuPont of Delaware, polyolefinmaterials that can include particulates like calcium carbonate, andothers. The level of breathability and liquid impermeability can varyacross the outer cover 24 by varying the thickness of the impregnatedthermoplastic member 26 in the z direction.

[0065] With respect to impermeability, in one embodiment of the presentinvention, the thermoplastic member 26 can be manufactured from HYTRELthat is at least partially impregnated into a High Elongation Cardedpolypropylene nonwoven manufactured by BBA Nonwovens Inc. of SouthCarolina, having a basis weight of about 22 grams/meter². The resultingcomposite material can provide liquid impermeability from about 50 mm toabout 700 mm of Hydrostatic Head. The thickness of the thermoplasticmember 26 can vary from about 10 microns to about 35 microns for a 71%thickness variation, wherein a higher degree of impermeability can beprovided in areas of greater thickness. For example, in the crotch areaof diaper 10 where greater liquid impermeability is desired, thethickness of the thermoplastic member 26 can be greater than in otherareas of the outer cover 24. From the preceding embodiment one skilledin the art can see a wide range of liquid impermeability variation ispossible with this invention and all intermediate values within thisrange of about 50 mm to about 700 mm of Hydrostatic Head are alsocontemplated.

[0066] With respect to impermeability, in another embodiment of thepresent invention, the thermoplastic member 26 can be manufactured fromHYTREL that is at least partially impregnated into a High ElongationCarded polypropylene nonwoven manufactured by BBA Nonwovens Inc. ofSouth Carolina, having a basis weight of about 22 grams/meter². Theresulting composite material can provide liquid impermeability fromabout zero grams/meter² to about 5 grams/meter Dynamic FluidTransmission at an impact energy of about 1000 Joules/meter². Thethickness of the thermoplastic member 26 can vary from about 10 micronsto about 35 microns for a 71% thickness variation, wherein a higherdegree of impermeability can be provided in areas of greater thickness.For example, in the crotch area of diaper 10 where greater liquidimpermeability is desired, the thickness of the thermoplastic member 26can be greater than in other areas of the outer cover 24. From thepreceding embodiment one skilled in the art can see a wide range ofliquid impermeability variation is possible with this invention and allintermediate values within this range of about zero grams/meter² toabout 5 grams/meter². Dynamic Fluid Transmission at an impact energy ofabout 1000 Joules/meter² are also contemplated.

[0067] With respect to breathability, in one embodiment of the presentinvention, the thermoplastic member 26 can be manufactured from HYTRELthat is at least partially impregnated into a High Elongation Cardedpolypropylene nonwoven manufactured by BBA Nonwovens Inc. of SouthCarolina, having a basis weight of about 22 grams/meter². The resultingcomposite material can provide breathability, Moisture VaporTransmission Rate (MVTR), from about 2,000 grams per meter per 24 hoursto about 10,000 grams per meter² per 24 hours. The thickness of thethermoplastic member 26 can vary from about 10 microns to about 35microns for a 71% thickness variation, wherein higher degree ofbreathability can be provided in areas of lower thickness. For example,in the waist area of diaper 10 where greater breathability is desired,the thickness of the thermoplastic member 26 can be less than in otherareas of the outer cover 24. From the preceding embodiment one skilledin the art can see a wide range of MVTR variation is possible with thisinvention and all intermediate values within the full range of about2,000 grams per meter² per 24 hours to about 10,000 grams per meter² per24 hours are also contemplated.

[0068] As disclosed above, the new composite materials can providedesired elastic properties. For example, the waist elastic 14 of thediaper 10 shown in FIG. 1 includes a thermoplastic member 28 to providedesired elasticity of the waist 14, providing desired comfort,gasketing, and sustained fit. The elastic property of the waist elastic14 can be provided by a variety of thermoplastic elastomeric resinsproviding elastic properties across the thermoplastic member 28. In oneembodiment of the present invention the thermoplastic member 28 can bemanufactured from KRATON, styrenic block copolymer, available from ShellCorporation, that is at least partially impregnated into a HighElongation Carded polypropylene nonwoven manufactured by BBA NonwovensInc. of South Carolina having a basis weight of about 22 grams/meter².The resulting composite material can provide elastic force at 200%elongation from about 400 grams/25.4 mm width to about 1000 grams/25.4mm width. The width 46 of the thermoplastic member 28, generallyperpendicular to the direction of stretch forces, can vary from about 2mm to about 200 mm and the thickness of the thermoplastic member 28 canvary from about 30 microns to about 150 microns for an 80% thicknessvariation, wherein a greater degree of elastic force can be provided inareas of greater thickness and/or area. For example, in the back waistarea 40 of the diaper 10 where a greater elastic force can be desired,the thickness and/or width of the thermoplastic member 28 can be greaterthan in other areas of the waist 14.

[0069] In another example of utilizing elastic properties, the elasticleg cuff 12 of the diaper 10 shown in FIG. 1, includes a thermoplasticmember 42 to provide desired elasticity of the elastic leg cuff 12providing desired comfort and gasketing. The elastic property of theelastic leg cuff 12 can be provided by a variety of thermoplasticelastomeric resins providing elastic properties across the thermoplasticmember. In one embodiment of the present invention, the thermoplasticmember 42 can be manufactured from KRATON styrenic block copolymeravailable from Shell Corporation, that is at least partially impregnatedinto a High Elongation Carded polypropylene nonwoven manufactured by BBANonowovens Inc. of South Carolina, having a basis weight of about 22grams/meter². The resulting composite material can provide elastic forceat 200% elongation from about 50 grams/25.4 mm width to about 100grams/25.4 mm width. The width of the thermoplastic member 42,perpendicular to the direction of stretch forces, can vary from about 2mm to about 20 mm and the thickness of the thermoplastic member 42 canvary from about 30 microns to about 150 microns for an 80% thicknessvariation, wherein a greater degree of elastic force can be provided inareas of greater width and/or thickness. For example, in the back legarea 44 of the diaper 10 where a greater elastic force can be desired,the thickness and/or width of the thermoplastic member 42 can be greaterthan in other areas of the elastic leg cuff 12.

[0070] In yet another example of utilizing elastic properties, theelastic side panel 16 of the diaper 10 shown in FIG. 1 includesthermoplastic member 48 to provide desired elasticity of the elasticside panel 16, providing desired comfort and sustained fit. The elasticproperty of the elastic side panel 16 can be provided by a variety ofthermoplastic elastomeric resins providing elastic properties across thethermoplastic member. In one embodiment of the present invention thethermoplastic member 48 can be manufactured from KRATON styrenic blockcopolymer available from Shell Corporation, that is at least partiallyimpregnated into a High Elongation Carded polypropylene nonwovenmanufactured by BBA Nonwovens Inc. of South Carolina, having a basisweight of about 22 grams/meter². The resulting composite material canprovide elastic force at 200% elongation from about 100 grams/25.4 mmwidth to about 500 grams/25.4 mm width. The width of the thermoplasticmember 48, perpendicular to the direction of stretch forces, can varyfrom about 2 mm to about 200 mm, and the thickness of the thermoplasticmember 48 can vary from about 30 microns to about 150 microns for an 80%thickness variation, wherein a greater degree of elastic force can beprovided in areas of greater width and/or thickness.

[0071] The above composite materials can be manufactured by a process 50of the present invention, one embodiment of which is illustratedschematically in FIG. 5. The process 50 is capable of at least partiallyimpregnating thermoplastic members into one or more fibrous substrates.The thermoplastic members can be impregnated into the fibrous substratethrough a variety of means suitable for supplying and depositing moltenthermoplastic resins. The means can include ink jet, spraying, coating,screen-printing, intaglio printing, flexographic printing, and the like.In the preferred embodiment of the present invention, the means ofsupplying and depositing molten thermoplastic resins can be provided bya rotogravure printing process because it provides flexibility indesired x-y dimensions of the thermoplastic member and desired quantityof deposition of the molten thermoplastic resin.

[0072]FIG. 5 shows a fibrous substrate 36, which can be provided by asupply roll 52, moving through a rotogravure printing device 54 thatdeposits molten thermoplastic members 60 onto the fibrous substrate 36to at least partially impregnate the fibrous substrate 36. Then, ifdesired, a fibrous substrate 34, which can be provided by a supply roll56, can be combined with the substrate 36 to cover the moltenthermoplastic member 60 and allow the molten member 60 to at leastpartially impregnate into the substrate 34 to form a composite material38.

[0073] The degree of impregnation of both substrates 34 and 36 by themolten thermoplastic member 60 can be controlled by applying a desiredpressure onto the composite material 38 to effect the impregnation. Asdescribed above, the substrates 34 and 36 can be any suitable fibroussubstrate in any suitable combination. (Alternatively, compositematerials of the present invention can include materials, wherein atleast one substrate is fibrous. Nonfibrous substrates can include films,foils, foams, and the like.) The source of the pressure can be anysuitable means, including contacting or noncontacting means. FIG. 5shows an example of a contacting means provided by a nip roll pair 58which can be heated or chilled. Further, the degree of impregnation canbe effected by the viscosity of the molten thermoplastic member 60, theporosity of the fibrous substrates 34 and 36, and the surface tension ofboth the molten thermoplastic member 60 and the fibrous substrates 34and 36. The rotogravure-printing device 54 can be any suitableconventional thermal rotogravure device. One suitablerotogravure-printing device can be obtained from Roto-Therm Inc. ofCalifornia.

[0074]FIG. 6 illustrates a magnified view of a rotogravure pattern 70for depositing the molten thermoplastic member 60. As shown, the cells72 are preferably intersecting with each other to provide a contiguousdistribution of the molten thermoplastic member 60 along the rotogravurepattern 70, which result in a contiguous distribution of the moltenthermoplastic resin in the thermoplastic member 60.

[0075] For example, the composite material 38 (FIGS. 2-4) of the slotand tab fastening system 18 (FIG. 1) can be manufactured by the aboveprocess 50 (FIG. 5) utilizing two substrates 34 and 36, moltenthermoplastic member 60, and subsequent compression of the compositematerial 38. Further, the breathable region 25 (FIG. 1) of the outercover 24 can be manufactured by the above process utilizing preferably asingle fibrous substrate 36 and a rotogravure pattern of the desiredshape (in the form of the breathable region 25). Furthermore, thecomposite material of the elastic waist 14 and the elastic leg cuff 12can be manufactured by the above process utilizing either one or morefibrous substrates and respective shapes of rotogravure patterns.Similarly, the composite material of the elastic side panel 16 can bemanufactured by the above process using one or more fibrous substratesand respective shapes of the rotogravure patterns.

[0076] In addition, the elastic properties of the leg elastic 12, thewaist elastic 14, and the side panel elastic 16 can be provided byvarious secondary operations, including incremental stretching of thecomposite material to permanently elongate the fibrous substrate toenable the thermoplastic member to stretch within the providedelongation of the substrate. Alternatively, prior to depositing themolten thermoplastic member, the fibrous substrates can be strained toconsolidate the fibrous substrate in the cross direction, which afterdeposition of the molten thermoplastic member, can expand under a forcein the cross direction to enable the thermoplastic member to stretchwithin the provided expansion of the substrate.

[0077]FIG. 7 illustrates another process embodiment of the presentinvention showing the use of multiple deposition devices 54 and 55, toprovide multiple depositions of one or more thermoplastic materials ontoa substrate 36, and then combining with a substrate 34, and/or makingseveral subsequent depositions onto the same substrate.

[0078]FIG. 8 illustrates yet another process embodiment of the presentinvention showing the use of multiple deposition devices 54 and 57, toprovide multiple depositions of one or more thermoplastic materials ontoone or more substrates 36 and 34, including deposition onto two or moresubstrates separately and then combining them. Further, the use ofmultiple deposition devices can provide a greater deposition weight ofthe molten thermoplastic material, a greater z dimension profilevariation, capability to deposit different thermoplastic materials, andcapability to deposit thermoplastic materials of different colors, andany combinations thereof.

Test Procedures Liquid Impermeability (Hydro-Head Test)

[0079] The test method used by the inventors is the following methodderived from ASTM D751 titled Standard Test Method for Coated Fabrics,section titled Pressure Application by a Rising Column of Water,procedure B1.

[0080] The test principle is to increase an adjustable water head ofdistilled water on the top side of a test specimen of about 64 cm², suchas a film or an other porous material.

[0081] A test specimen is cut to about 10 cm by 10 cm with a centeredO-ring seal of about 8 cm diameter. The sample plate has a centeredopening of about 7.6 cm diameter to allow observation of the bottom sideof the test specimen during the test. The sample plate is carefullypositioned under a 7.6 cm inner diameter Perspex column of about 1 mheight, with a mounting flange so as to conveniently allow tightening ofthe sample plate carrying the sample underneath by means of screws.Optionally, a mirror can be positioned under the opening in the sampleplate to ease the observation.

[0082] The Perspex column has a sideways-oriented opening of about 1 cmdiameter to allow connection to a pump, about 1 cm above the sample whenmounted. Optionally, a three-way-valve can be mounted in this connectionto allow easier emptying of the column after the test.

[0083] The pump is set to raise the liquid head in the Perspex column to25.4 cm within 60+/−2 seconds. Upon starting of the pump the bottomsurface of the test specimen is watched. Upon the first drop of waterfalling off of the test specimen, the pump is immediately stopped andthe height in the Perspex column is recorded in units of mm.

[0084] For each material, the test should be repeated for five samplesand the results should be averaged.

Tensile Properties

[0085] Depending on the thickness and choice of polymeric materials,suitable test methods can include the following methods: ASTM D882titled Standard Test Method for Tensile Properties of Thin PlasticSheeting; ASTM D638 titled Standard Test Method for Tensile Propertiesof Plastics; ASTM D3039/D3039M titled Standard test Method for TensileProperties of Polymer Matrix composite Materials; and ASTM D76 titledStandard Specification for Tensile Testing Machines for Textiles.Tensile at break data is reported in force per cross sectional area, MPa(Pascal×10⁶). The cross sectional area is perpendicular to the directionof force.

[0086] For each material, the test should be repeated for five samplesand the results should be averaged.

Flexural Modulus

[0087] The test method used by the inventors is the following methodderived from ASTM D790 titled Standard Test Method for FlexuralProperties of Unreinforced and Reinforced Plastics and ElectricalInsulating Materials. This test method utilizes a three-point loadingsystem applied to a simply supported beam. One suitable test machine,available from Rheometric Scientific Inc. of New Jersey, is the DMTAMkIV. The sample preparation, formulas, and operating range can be foundin the DMTA hardware manual 902-50001 Rev A.1 dated January 1997.Flexural modulus data is reported in units of (MPa). The cross sectionalarea is perpendicular to the bending plane For each material, the testshould be repeated for 5 samples and the results should be averaged.

Moisture Vapor Transmission Rate (MVTR)

[0088] The test method used by the inventors is the following methodderived from ASTM E90 titled Standard Test Methods for Water VaporTransmission of Materials, section titled Standard Desiccant testmethod.

[0089] A known amount of CaCl₂ is put into a flanged cup. A samplematerial is placed on top of the cup and held securely by a retainingring and gasket. The assembly is then weighed and recorded as theinitial weight. The assembly is placed in a constant temperature (40 degC.) and humidity (75% RH) for five (5) hours. The assembly is thenremoved from the chamber and allowed to equilibrate for at least 30minutes at the temperature of the room where the balance is located. Theassembly is then weighed and recorded as the final weight. The moisturevapor transmission rate is calculated and expressed in g/m²/24 hours

MVTR=(final weight−initial weight)×24.0)/area of sample in meters^ 2×5.0(time in chamber).

[0090] For each material, the test should be repeated for 5 samples andthe results should be averaged.

Elastic Properties

[0091] The test method used by the inventors is the following methodderived from ASTM D412-98a titled Standard Test Method for VulcanizedRubber and Thermoplastic Rubbers and Thermoplastic Elastomers-Tension;ASTM D1566 titled Standard Terminology Relating to Rubber; and ASTM D76titled Standard Specification for Tensile Testing Machines for Textiles.

[0092] Samples of 1″ by 3″ (25.4 mm by 76.2 mm) size are obtained fromthe elastic region of the composite. Because the elastic composite hasdirectional properties, which are dependent on the orientation of thesample with respect to the orientation of the elastic members within thesample, samples are prepared with four different orientations. Namely,samples are obtained from the elasticized region with its longitudinalaxis aligned in the machine direction (MD), the cross-machine direction(CD), and +/−45 degrees with respect to the machine direction, whereinthe machine direction is the substrate movement direction during theprocess of applying the elastic members to the substrate. At least threesamples along each orientation are prepared. If a 1″ by 3″ elasticizedarea is not available, the largest possible sample size is used fortesting, and the test method is adjusted accordingly. All surfaces ofthe sample should be free of visible flaws, scratches or imperfections.

[0093] A commercial tensile tester from Instron Engineering Corp.,Canton, Mass. or SINTECH-MTS Systems Corporation, Eden Prairie, Minn.may be used for this test. The instrument is interfaced with a computerfor controlling the test speed and other test parameters, and forcollecting, calculating and reporting the data. The tensile propertiesare measured under typical laboratory conditions (i.e., about 20 degreesC. and about 50% relative humidity). The procedure is as follows:

[0094] (1) choose appropriate jaws and load cell for the test; the jawsshould be wide enough to fit the sample, typically 1″ wide jaws areused; the load cell is chosen so that the tensile response from thesample tested will be between 25% and 75% of the capacity of the loadcells or the load range used, typically a 50 lb load cell is used;

[0095] (2) calibrate the instrument according to the manufacturer'sinstructions;

[0096] (3) set the gauge length at 1″ (25.4 mm);

[0097] (4) place the sample in the flat surface of the jaws such thatthe longitudinal axis of the sample is substantially parallel to thegauge length direction;

[0098] (5) set the cross head speed at a constant speed of 10″/min(0.254 m/min) until it reaches 112% strain; then return to the originalgauge length at 10″/min (0.254 m/min); and at the end of thispre-straining cycle, start timing the experiment using a stop watch;

[0099] (6) reclamp the pre-strained sample to remove any slack and stillmaintain a 1″ (25.4 mm) gauge length;

[0100] (7) at the three minute mark on the stop watch, start stretchingthe sample at a constant speed of 10″/min (0.254 m/min); the instrumentrecords the load versus strain during this cycle; and

[0101] (8) calculate and report the load at 200% strain in grams/25.4 mmwidth.

[0102] For the elastic members, the average result of three samples isreported. For the elastic composite, the results from three sampleshaving a given orientation are averaged; the maximum value among thoseaverages is reported as the directional load at 200% strain.

Impregnated Member Thickness (Magnification Method)

[0103] The test method used by the inventors is the following methodderived from ASTM B748 Standard Test Method for Measurement of Thicknessof Metallic Coatings by Measurement of Cross Section with a ScanningElectron Microscope and ASTM E766, titled Practice for Calibrating theMagnification of a Scanning Electron Microscope. The test principle isto examine sample cross sections under magnification to determinedimensions such as, thickness, width, or cross sectional area ofimpregnated polymeric members (excluding non-impregnated portions of asubstrate).

[0104] A sample containing the impregnated member can be immersed inliquid nitrogen for 30 seconds, and then a cross section, in the planeof the desired dimension, can be cut with a sharp razor from the desiredlocation on the impregnated member. The cross section sample can bemounted onto a conductive tape such as #16084-2 from Ted Pella Inc. ofCalifornia, and then placed onto a Scanning Electron Microscope (SEM)mount stage. The cross section sample can then be gold plated by using avacuum plasma-coating unit such as Denton Vacuum DESK II from DentonInc. of New Jersey using instructions provided by the manufacturer.

[0105] The sample can be observed and recorded using the instructions ofthe manufacturer of the SEM. A suitable SEM test apparatus S-3500N canbe available from HITACHI of Japan. The sample can be analyzed andrecorded at a magnification from about 50× to about 300×. Magnificationis adjusted such that the full length of the dimension of interest is inthe field of view. The photomicrograph recorded for each sample can bestored as an electronic file at a resolution recommended by themanufacturer of the SEM.

[0106] The photomicrograph electronic file for each sample can beimported into a software application for measuring dimensions, such asQuartz PCI version 4.20 from Quartz Imaging Corporation of VancouverBritish Columbia. Because of the roughness of the interface between theimpregnated member and the fibrous substrate, multiple measurements inthe location of interest are taken and then averaged to determine thedimension. Dimensions can be recorded to the nearest 10 microns.

[0107] For each cross sectional sample, five typical locations for thedimensions of interest should be measured and the results should beaveraged.

Basis Weight

[0108] The test method used by the inventors is the following derivedfrom ASTM D646, titled Standard Test Method for Grammage of Paper andPaperboard (Mass Per Unit Area).

[0109] Ten samples of the test material are cut to the desireddimensions (10 cm×10 cm) with a precision (+/−0.1 mm) die rule press.The samples are laid onto a calibrated gravimetric scale that reads tothe nearest 0.001 grams. The weight of the 10 samples can be multipliedby 10 and recorded as basis weight in grams/meter².

Dynamic Fluid Impact Test

[0110] The dynamic fluid impact test method set forth below is designedto mimic the energy per area that an infant imparts to a diaperbacksheet when abruptly going from a standing to a sitting position.

[0111] The dynamic fluid impact test method utilizes the apparatus 100shown in FIG. 9. An absorption material 102 weighed to the nearest0.0001 gram is placed directly on top of the energy absorbing impact pad103. To this purpose, the absorption material 102 can comprise a No. 2filter paper available from Whatman Laboratory Division, Distributed byVWR Scientific of Ohio. The absorption material should be able to absorband retain the simulated urine, which passes through the backsheetmaterial being tested. The energy absorbing impact pad 103 is a carbonblack filled cross linked rubber foam. The about 5 inch by about 5 inch(125 mm by 125 mm) square impact pad has a density of about 0.1132grams/cm³ and a thickness of about 0.3125 inches (7.9375 mm). The impactpad 103 has a Durometer Value of A/30/15 according to ASTM 2240-91.

[0112] A circular absorbent core material 104 measuring about 2.5 inches(63.5 mm) in diameter is weighed. To this purpose, the absorbent corematerial can comprise individualized, crosslinked wood pulp cellulosicfibers as described in U.S. Pat. No. 5,137,537 issued to Herron et al.on Aug. 11, 1992. The absorbent core has a basis weight of about 228grams/m². The absorbent core material is then loaded with simulatedurine to about (10) times its dry weight. This represents an absorbentcore sufficiently loaded with urine. The absorbent core material shouldbe able to hold a sufficient amount of simulated urine, e.g., at leastabout ten times its dry weight. Accordingly, other absorbent corematerials currently used in commercial diapers may also be used as theabsorbent core material. The simulated urine can comprise distilledwater.

[0113] A section of the backsheet material 105 to be tested is placedface down with the outside surface on a clean and dry tabletop. Theloaded core material 104 is placed directly in the center of thebacksheet material 105. The backsheet/core arrangement is then securedto the impact portion 107 of the impact arm 108 with a rubber band 109.The backsheet/core arrangement is positioned such that the core 104 isadjacent to the bottom surface 110 of the impact portion 107. The impactarm 108 is raised to a desired impact angle to provide the desiredimpact energy. The impact arm 108 is then dropped and a stopwatch isactivated on impact. The arm then rests on the filter paper 102 for tenseconds. The impact arm 108 is then raised and the filter paper 102 isremoved and placed on a digital scale. The mass of the wet filter paperis recorded at the three minute mark. The dynamic fluid transmissionvalue (DFTV) is calculated and expressed in grams/m² at a specificimpact energy expressed in Joules/m² using the following formula:

DFTV=(mass of wet filter paper−mass of dry filter paper)/impact area

[0114] The impact area, expressed in m², is the area of the bottomsurface 110 of the impact portion 107. The impact area is 0.00317 m².The absorbent core material 104 should have an area slightly larger thanthat of the impact area of the surface 110.

[0115] While particular embodiments and/or individual features of thepresent invention have been illustrated and described, it would beobvious to those skilled in the art that various other changes andmodifications can be made without departing from the spirit and scope ofthe invention. Further, it should be apparent that all combinations ofsuch embodiments and features are possible and can result in preferredexecutions of the invention. Therefore, the appended claims are intendedto cover all such changes and modifications that are within the scope ofthis invention.

What is claimed is:
 1. An article comprising one or more shapedthermoplastic members at least partially impregnated into one or morefibrous substrates forming a composite material, wherein the shapedthermoplastic members have a profiled thickness providing variation inmaterial properties, and wherein a percent variation of the profiledthickness of the thermoplastic member can vary from about 5% to about95%.
 2. The article of claim 1, wherein the percent variation variesfrom about 20% to about 80%.
 3. The article of claim 1, wherein thecomposite material comprises a stiffening region of the article having amodulus of elasticity from about 350 MPa to about 8000 MPa.
 4. Thearticle of claim 1, wherein the composite material comprises a slot andtab fastening system having a modulus of elasticity from about 350 MPato about 8000 MPa.
 5. The article of claim 1, wherein the compositematerial comprises a stiffening region having a tensile strength fromabout 25 MPa to about 6000 MPa.
 6. The article of claim 1, wherein thecomposite material forms a breathable region of the article having amoisture vapor transmission rate of about 2,000 grams per m² per 24hours to about 10,000 grams per m² per 24 hours (MVTR).
 7. The articleof claim 1, wherein the composite material forms a breathable and liquidimpermeable region of the article having a hydrostatic head from about50 mm of water to about 700 mm of water.
 8. The absorbent article ofclaim 1, wherein the composite material forms a breathable and liquidimpermeable region of the article having a dynamic fluid transmissionvalue from about 0 grams/m² to about 5 grams/m² at an impact energy of1000 Joules/m².
 9. The article of claim 1, wherein the compositematerial forms an elastic region of the article having an elastic forceat 200% elongation from about 50 grams/25.4 mm width to about 1000grams/25.4 mm width.
 10. The article of claim 1, wherein the compositematerial forms an elastic leg cuff region of the article having anelastic force at 200% elongation from about 50 grams/25.4 mm width toabout 100 grams/25.4 mm width.
 11. The article of claim 1, wherein thecomposite material forms a waist elastic having an elastic force at 200%elongation from about 400 grams/25.4 mm width to about 1000 grams/25.4mm width.
 12. The article of claim 1, wherein the composite materialforms an elastic side panel having an elastic force at 200% elongationfrom about 100 grams/25.4 mm width to about 500 grams/25.4 mm width. 13.The article of claim 1, wherein the shaped thermoplastic member has ashape selected from the group consisting of an area having a rectilinearoutline, a curvilinear outline, a triangle, a square, a trapezoid, aparallelogram, a polygon, a circle, an ellipse, and any combinationthereof.
 14. The article of claim 1, wherein the shaped thermoplasticmember has at least one void defined by a shape selected from the groupconsisting of an area having a rectilinear outline, a curvilinearoutline, a triangle, a square, a trapezoid, a parallelogram, a polygon,a circle, an ellipse, and any combination thereof.
 15. The article ofclaim 1, wherein the shaped thermoplastic member comprises a materialselected from the group consisting of a thermoplastic polymer, athermoplastic elastomer, a superabsorbent polymer, a polyolefin, apolyester, a polyamide, a polyurethane, a hot melt adhesive, and anymixture or combination thereof.
 16. The article of claim 1, wherein thefibrous substrate is selected from the group consisting of a polymericmaterial, a natural material, a woven fabric, a non-woven fabric, a knitfabric, cellulose material, and any combination thereof.
 17. The articleof claim 1, wherein the article is selected from the group consisting ofbaby diapers, adult incontinence articles, feminine hygiene articles,baby swim diapers, dining bibs, wound dressings, sports wear,undergarments, outer wear, rain coats, hospital garments, and cleansingwipes.
 18. An article comprising one or more shaped thermoplasticmembers at least partially impregnated into one or more fibroussubstrates forming a composite material, wherein the shapedthermoplastic members have a profiled basis weight providing variationin material properties, and wherein a percent variation of the profiledbasis weight of the thermoplastic member can vary from about 5% to about95%.
 19. A method of making a composite material comprising at least oneshaped thermoplastic member impregnated into at least one fibroussubstrate, the method comprising the steps of: e) providing a firstfibrous substrate; f) depositing a first thermoplastic material on thefirst fibrous substrate to form at least one shaped thermoplastic memberhaving a profiled thickness providing variation in material properties,wherein a percent variation of the profiled thickness of thethermoplastic member can vary from about 5% to about 95%, and whereinthe step of depositing is selected from a group consisting of intaglioprinting, gravure printing, screen printing, ink jet printing, andflexographic printing; g) providing a second substrate; and h) combiningthe first substrate and the second substrate to form the compositematerial, wherein the thermoplastic member is at least partiallyimpregnated into the first substrate.
 20. The method of claim 19,wherein the thermoplastic material is at least partially impregnatedinto the second substrate.
 21. The method of claim 19, wherein thepercent variation varies from 20% to 80%.
 22. The method of claim 19,wherein the second substrate is not fibrous.
 23. The method of claim 19,wherein the second substrate is fibrous.
 24. The method of claim 19further comprising a step of depositing a second thermoplastic materialon the second fibrous substrate to form a second shaped thermoplasticmember, wherein the step of depositing is selected from a groupconsisting of intaglio printing, gravure printing, screen-printing, inkjet printing, and flexographic printing.
 25. The method of claim 24,wherein the first thermoplastic member and the second thermoplasticmember are different materials.
 26. The method of claim 19 furthercomprising a step of depositing a second thermoplastic material on thefirst fibrous substrate on top of the first shaped thermoplastic member,wherein the step of depositing is selected from a group consisting ofgravure printing, screen-printing, ink jet printing, and flexographicprinting.
 27. The method of claim 26, wherein the first shapedthermoplastic member and the second shaped thermoplastic member aredifferent materials.
 28. The method of claim 26, wherein the firstshaped thermoplastic member and the second shaped thermoplastic memberare same materials.
 29. A composite material comprising one or moreshaped thermoplastic members at least partially impregnated into one ormore fibrous substrates forming the composite material, wherein theshaped thermoplastic members have a profiled thickness providingvariation in material properties, and wherein a percent variation of theprofiled thickness of the thermoplastic member can vary from about 5% toabout 95%.
 30. The composite material of claim 29, wherein the percentvariation varies from about 20% to about 80%.
 31. The composite materialof claim 29, wherein the shaped thermoplastic member has a shapeselected from the group consisting of an area having a rectilinearoutline, a curvilinear outline, a triangle, a square, a trapezoid, aparallelogram, a polygon, a circle, an ellipse, and any combinationthereof.
 32. The composite material of claim 29, wherein the shapedthermoplastic member has at least one void defined by a shape selectedfrom the group consisting of an area having a rectilinear outline, acurvilinear outline, a triangle, a square, a trapezoid, a parallelogram,a polygon, a circle, an ellipse, and any combination thereof.
 33. Thecomposite material of claim 29, wherein the shaped thermoplastic membercomprises a material selected from the group consisting of athermoplastic polymer, a thermoplastic elastomer, a superabsorbentpolymer, a polyolefin, a polyester, a polyamide, a polyurethane, a hotmelt adhesive, and any mixture or combination thereof.
 34. The compositematerial of claim 29, wherein the fibrous substrate is selected from thegroup consisting of a polymeric material, a natural material, a wovenfabric, a non-woven fabric, a knit fabric, cellulose material, and anycombination thereof.
 35. The composite material of claim 29, comprisingat least one region selected from the group consisting of a stiffeningregion having a modulus of elasticity from about 350 MPa to about 8000MPa, a breathable region having a moisture vapor transmission rate ofabout 2000 grams/m2/24 hours to about 10000 grams/m2/24 hours, abreathable region having a liquid barrier hydrostatic head of about 50mm of water to about 700 mm of water, a breathable region having adynamic liquid impact from about 0 grams to about 5 grams, an elasticregion having an elastic force at about 200% elongation from about 50grams/25.4 mm to about 1000 grams/25.4 mm, and a stiffening regionhaving a tensile strength from about 350 MPa to about 6000 MPa.